Blower tray

ABSTRACT

Methods, systems, and apparatus, including a housing defining a top surface, a bottom surface, and first and second side surfaces. Also included is a first rail extending from the first side surface and a second rail extending from the second surface such that when the first and second rails are slidably engaged with a third surface. A blower device is included that is axially disposed between the top and bottom surface, wherein a first end of the housing defines a first plenum outlet, the top surface defines a plenum inlet, the bottom surface defines a second plenum outlet that is positioned on a second side of the blower device and that fluidly couples the first plenum chamber to the second plenum chamber. Further, the second plenum chamber is formed by the first and second rails, the bottom surface and the third surface has a third plenum outlet.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation application of, and claims priorityto, U.S. patent application Ser. No. 14/852,989, titled “BLOWER TRAY,”filed on Sep. 14, 2015. The disclosure of the foregoing application isincorporated herein by reference in its entirety for all purposes.

BACKGROUND

Cooling of computing devices, such as computer towers and chassis, isrequired for the proper functioning of the computing device. Ascomputing devices are operating, heat is produced by the operatingcomponents within the computing devices. Computing devices may have fanswithin them to cause air to flow around the components of the computingdevice to provide cooling. The fan may be operatively coupled to plenumsto draw air through the computing device to facilitate cooling.

Often computing devices are arranged to maximize the use of availablespace, such as in a server farm. This has led to the development of highdensity racks with multiple processing trays. The resulting space withinthe racks for the blower fans has thus been reduced, which, in turn,leads to a reduced efficiency in the operation of blower fans.

SUMMARY

This specification describes technologies relating to blower trayapparatus. In general, one innovative aspect of the subject matterdescribed in this specification includes a housing defining a topsurface, a bottom surface, and first and second side surfaces connectedthe top surface and the bottom surface and defining a first plenumchamber between the top, bottom and first and second surfaces. Alsoincluded is a first rail extending from the first side surface and asecond rail extending from the second surface such that when the firstand second rails are slidably engaged with a third surface that is inparallel disposition to the bottom surface, the first and second rails,the bottom surface and the third surface define a second plenum chamber.A blower device is included that is axially disposed between the top andbottom surface such that an axis of rotation of a blower fan of theblower device is substantially perpendicular to the top surface and thebottom surface, wherein a first end of the housing defines a firstplenum outlet for the first plenum chamber on a first side of the blowerdevice, the top surface defines a plenum inlet that is aligned with theblower fan so that the plenum inlet is over at least a portion of theblower fan, the bottom surface defines a second plenum outlet that ispositioned on a second side of the blower device that is opposite thefirst side of the blower device and that fluidly couples the firstplenum chamber to the second plenum chamber formed by first and secondrails, the bottom surface and the third surface. Further, the secondplenum chamber is formed by the first and second rails, the bottomsurface and the third surface has a third plenum outlet. Particularembodiments of the subject matter described in this specification can beimplemented so as to realize one or more of the following advantages.The blower tray apparatus enables high airflow rate and high pressureresistance levels while facilitating a blind mate connection for powerand control connections. This results in a hot-swappable blower trayassembly. The blower tray apparatus thus enables cooling of a highdensity electronics chassis and equipment that have a high availabilityrequirement.

The performance of blowers degrades as the housing clearance to theblower fan blade drops below 0.5× diameter of the blower fan. However,the blower tray apparatus described in this document has a unique plenumarrangement that overcomes the performance degradation when there isotherwise insufficient space to provide housing clearance. Thus, the useof a blower tray apparatus, as described in this document, allows for areduction in the required width of air chamber(s) and air outlet(s) influid communication with the blower fan. The blower tray apparatus, asdescribed herein, can be used with a narrow chassis and produce the same(or nearly the same) airflow capabilities as a larger chassis that wouldotherwise be required.

The compact blower tray apparatus described in this document, incombination with the blind mate connectors, allows for easy and quickremoval and replacement, thus realizing a high mechanical efficiency inspite of the compact form factor. Furthermore, the blower tray apparatusis low cost and simple to manufacture. Additionally, the resultingplenums and fluid couplings reduces back pressure on the blower modulethat would otherwise be present in the absence of such advantageouslyarranged couplings. The reduction in back pressure results in areduction in the power consumed by the blower tray apparatus.

Finally, a planar gasket disposed on the blower tray apparatus inlet ishighly reliable and provides for a highly efficient gasket seal.

The details of one or more embodiments of the subject matter describedin this specification are set forth in the accompanying drawings and thedescription below. Other features, aspects, and advantages of thesubject matter will become apparent from the description, the drawings,and the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a perspective view of a blower tray apparatus from a back endof the blower tray apparatus.

FIG. 1B is a perspective view from underneath the blower tray apparatus.

FIG. 2A is a perspective side view of multiple blower tray apparatus ina chassis with a cut away section.

FIG. 2B is a perspective view with a cut away section from one end ofthe chassis with a blower tray apparatus connected in the chassis.

FIG. 3 is a flow diagram of drawing air to and passing the air through ablower tray apparatus.

Like reference numbers and designations in the various drawings indicatelike elements.

DETAILED DESCRIPTION

This document describes apparatus, systems, and methods for a blowertray apparatus that may be used with a chassis and draw air, forexample, and into the chassis, and through the blower tray apparatus.These features and additional features are described in more detailbelow.

FIG. 1A is a perspective view of a blower tray apparatus 100 from a backend of the blower tray apparatus. The blower tray apparatus 100 includesa housing 110 that includes a top surface 112, a bottom surface 114, afirst side surface 116, and a second side surface 118. The top surface112, in the current implementation, includes edges 112 a, 112 b, 112 c,and 112 d. The bottom surface 114, in the current implementation,includes edges 114 a and 114 b and corresponding opposite edges (notshown). First side 116 includes edges 116 a, 116 b, 116 c, and 116 d.Second side 118 includes edges 118 a and 118 b and correspondingopposite sides. The top surface 112 is substantially parallel to thebottom surface 114, and the first side surface 116 is parallel to thesecond side surface 118 as shown. The housing 110 may be made of metal,plastic, a combination thereof, or any other material and structure thatmay direct airflow.

The housing 110 defines a plenum chamber 120 between the top surface112, bottom surface 114, and first and second side surfaces 116, 118.The plenum chamber 120 includes a blower device 122 (shown in FIG. 1B)that may draw air from outside of the plenum chamber 120 into the plenumchamber 120. The blower device 122 includes a blower fan 124 that drawsthe air to the blower device 122, and the blower device 122 may includeone or more openings 125 a, 125 b, and 125 c, from the blower fan 124 tothe plenum chamber 120. The blower fan 124 is axially disposed betweenthe top surface 112 and the bottom surface 114 such that an axis ofrotation of a blower fan 124 is substantially perpendicular to the topsurface 112 and the bottom surface 114.

The top surface 112 includes a plenum inlet 126 that enables the blowerfan 124 to draw air from outside of the plenum chamber 120. The plenuminlet 126 may be of different shapes and sizes, and the plenum inlet 126is aligned with the blower fan 124 so that the inlet is located over atleast a portion of the blower fan 124 for the blower fan 124 to draw airinto the plenum chamber 120 from outside of the plenum chamber 120.

Additionally, the housing 110 includes a plenum outlet 128 that is anopening that may extend substantially parallel to the radial axis of theblower device 122 and be defined by the edges 112 d, 114 b, 116 c and118 b. The plenum outlet 128 and a front side 140 are positioned onlongitudinally opposite sides of the blower device 122 relative to oneanother so that the plenum outlets 128 is located at the “back end” ofthe blower tray apparatus 100.

As will be describe with reference to the chassis 210 (shown in FIG.2A), the blower tray apparatus 100 will form another plenum 130 whenslidably engaged with a third surface of the chassis 210. The thirdsurface, also referred to as an assembly surface 131 is represented bythe phantom line 131 and is in parallel disposition to the bottomsurface 114 of the blower tray apparatus 100. The plenum chamber 130 isthus defined by a first rail 132 that extends from edge 116 b of thefirst side 116 and a second rail 134 that extends from edge 118 b of thesecond side 118, the top surface 114, and the third surface 131 whenslidably engaged with the chassis 210. The first rail 132 includes edgesand the second rail 134 includes edges 134 a, 134 b, 134 c, and 134 d.The first rail 132 and second rail 134 may be substantially parallelwith the first side 116 and second side 118.

The first rail 132 and the second rail 134 are configured to engage withguides on the chassis 210. For example, the first rail 132 and thesecond rail 134 may slidably engage respective engagement surfaces inthe chassis 210, such as engagement surface 231 and as described furtherbelow. Once the blower tray assembly 100 is inserted into the chassis,the plenum chamber 130 is defined by the assembly surface 131, the firstrail 132, the second rail 134 and the bottom surface 114. In the currentimplementation, plenum chamber 130 may be of a smaller volume than ofthe volume of the plenum chamber 120; however, such a configuration isnot required, and in other implementations, different relative volumesof the plenum chamber 120 and the plenum chamber 130 may be used.

The plenum chamber 130 as formed includes a plenum outlet 138 that mayextend substantially parallel to the radial axis of the blower device122. In the implementation depicted, the outlet 138 is defined by theedges of the rails 132 and 134, the bottom surface edge 114 b, and theedge of the assembly surface 131.

The front side 140 of the housing 110 may form an end of the plenumchamber 130 such that the plenum chamber 130 may extend the length ofthe blower tray assembly 100. As will be described in more detail below,a portion of the plenum chamber 130 may be occupied by an assembly 161for an electrical connector 160 on the assembly 100 that mates with amating component 208 on the chassis 210.

Further, the plenum inlet 126 may include a gasket 145 to secure theplenum inlet 126 and provide a seal to prevent air and airflow fromentering any other place than the plenum inlet 126 or escaping from theblower device 122 or the plenum chamber 120. The gasket 145 mayperipherally surround the plenum inlet 126.

FIG. 1B is a perspective view from underneath the blower tray apparatus100. As seen in blower tray apparatus 100, plenum outlet 150 is includedbetween, and fluidly connects, plenum chamber 120 to plenum chamber 130when the plenum chamber 130 is formed. Plenum outlet 150 is an openinglocated in the bottom surface 114. In some implementations, plenumoutlet 150 is radially positioned on one side of the blower device 122that is opposite the side of the blower device 122 that is closest tothe plenum outlet 128. Plenum outlet 150 may be centrally positioned onthe bottom surface 114; however, such a positioning is not required, solong as the blower device 122 is interposed between the outlet 150 andthe outlet 128.

An electrical connector 160 may be fastened to the bottom surface 114 bya housing 161 and extend within a portion of plenum chamber 130. Theelectrical connector 160 may be positioned on a side of the plenumoutlet 150 that is opposite a side at which the blower device ispositioned longitudinally relative to the plenum outlet 150. In someimplementations, electrical connector 160 and housing 161 may extendwithin the plenum chamber 130 from the bottom surface 114 to a distancethat is less than or equal to the height of each of the first rail 132and the second rail 134 so that it may slide unimpeded into the chassis210. The electrical connector 160 is configured to meet a matingcomponent 280, shown in FIG. 2B, upon fully inserting the blower trayapparatus 100 into the chassis 210. As such, a blind mate connectionoccurs between the electrical connector 160 and the mating component280.

FIG. 2A is a perspective side view of multiple blower tray apparatus ina chassis with a cut away section. As seen in FIG. 2A, a chassis 210 maybe included with one or more blower tray apparatus assembled within thechassis. A chassis 210 may be a computer case that includes andencloses, for example, multiple components of a computer (e.g., acentral processing unit, memory, electrical circuits, etc.), or evenmultiple racks of computers or other computer devices.

The chassis 210, in the current implementation, includes end 211, side212, top surface 213, end 214, side 215, and bottom surface 216 (notshown). Side 212 is partially cut away to show the interior of thechassis 210. Side 215 may be the same as side 212 on the opposite sideof the chassis 210 as side 212, and side 214 may be substantiallyparallel to side 212 and substantially perpendicular to ends 211 and214. Each blower tray apparatus 100 is inserted in the chassis 210 in ablower tray slot 230 defined within the surfaces 211, 212, 214, and 215of the chassis 210.

A blower tray slot 230 may be defined by an interior surface 217, thetop surface 213, and sides 212 and 214. As shown in FIG. 2A, theinterior surface 217 is the assembly surface 131 as described in FIG. 1.Engagement surfaces, one of which is shown in phantom as 231, receiveand interact with slot rails 132 and 134 for slidable engagement.

Additionally, a chassis chamber 240 is defined between end 214, sides212 and 215, interior surfaces 217, interior surface 219, top surface213, and bottom surface 216. Interior surface 219 may include exhaustports 244 that define openings to allow air to travel from intake ports260 in the front of the chassis 210 and into the chassis chamber 240,which, in turn, provides for cooling of the components between the frontof the chassis 210 and the surface 219. The chassis chamber 240 includeschassis chamber exhaust ports 246 that enable air to travel from thechassis chamber 240 into the housing 110 of the blower tray apparatus100. The chassis chamber exhaust ports 246 are openings that align withthe plenum inlet 126 in order for air to travel into blower device 122for exhausting out the plenum outlets 128 and 138 through exhaust ports270.

Thus, once a blower tray apparatus 100 is inserted into the chassis 210and begins operating, air is drawn through the front of the chassis 210to the chamber 240, then through the port 246 and exhausted out theplenum outlets 128 and 138.

In particular, upon the air entering the chassis chamber 240, the one ormore blower tray apparatus 100 may draw the air through its blowerdevice 122 via the blower fan 124. A portion of the air that entersplenum chamber 120 will exit the plenum chamber 120 through plenumoutlet 128 and exit the chassis 210 through exhaust port 270.Additionally, the remaining portion of the air in plenum chamber 120will exit via plenum outlet 150 and enter plenum chamber 130 and exitvia plenum outlet 138.

FIG. 2B is a perspective view with a cut away section from one end ofthe chassis 210 with a blower tray apparatus 100 connected in thechassis. As seen in FIG. 2B, a mating component 280 is included in theblower tray slot 230. As the blower tray apparatus 100 is positionedwithin the blower tray slot 230 (e.g., via sliding the first rail 132and second rail 134 within rail slots 231 of the chassis 210), theelectrical connector 160 of the blower tray apparatus 100 aligns withthe mating component 280 of the chassis 210. The mating component 280may be connected to a bracket 285, as shown in FIG. 2B, to provide thealignment. Upon connection between the electrical connector 160 and themating component 280, the blower tray apparatus 100 has electrical power(e.g., provided by the chassis 210) and is controlled by the chassis 210(e.g., to speed up or slow down the blower fan 124).

FIG. 3 is a method flow diagram of drawing air to and passing the airthrough a blower tray apparatus 100. Air may be drawn, by a blower fan124 of the blower device 122, from a chassis chamber (e.g., chassischamber 240) in a chassis (e.g., chassis 210) into a plenum chamber 120of the blower tray apparatus 100 (302). A portion of the air drawn intothe plenum chamber 120 is exhausted through plenum outlet 128 (304). Theremaining portion of the air in plenum chamber 120 is exhausted throughplenum outlet 150 to plenum chamber 130, which is external to the blowertray apparatus 100 and the chassis chamber 240. The air in the plenumchamber 130 is exhausted through plenum outlet 138 (306). If the blowertray apparatus 100 is assembled in the chassis 210, then the air that isexhausted through plenum outlet 128 and plenum outlet 138 may beexhausted from the chassis 210 via one or more exhaust port 270.

While this specification contains many specific implementation details,these should not be construed as limitations on the scope of anyinventions or of what may be claimed, but rather as descriptions offeatures specific to particular embodiments of particular inventions.Certain features that are described in this specification in the contextof separate embodiments can also be implemented in combination in asingle embodiment. Conversely, various features that are described inthe context of a single embodiment can also be implemented in multipleembodiments separately or in any suitable subcombination. Moreover,although features may be described above as acting in certaincombinations and even initially claimed as such, one or more featuresfrom a claimed combination can in some cases be excised from thecombination, and the claimed combination may be directed to asubcombination or variation of a subcombination.

Similarly, while operations are depicted in the drawings in a particularorder, this should not be understood as requiring that such operationsbe performed in the particular order shown or in sequential order, orthat all illustrated operations be performed, to achieve desirableresults. In certain circumstances, multitasking and parallel processingmay be advantageous. Moreover, the separation of various systemcomponents in the embodiments described above should not be understoodas requiring such separation in all embodiments, and it should beunderstood that the described program components and systems cangenerally be integrated together in a single software product orpackaged into multiple software products.

Thus, particular embodiments of the subject matter have been described.Other embodiments are within the scope of the following claims. In somecases, the actions recited in the claims can be performed in a differentorder and still achieve desirable results. In addition, the processesdepicted in the accompanying figures do not necessarily require theparticular order shown, or sequential order, to achieve desirableresults. In certain implementations, multitasking and parallelprocessing may be advantageous.

What is claimed is:
 1. An apparatus, comprising: a housing defining atop surface, a bottom surface, and first and second side surfacesconnected the top surface and the bottom surface and defining a firstplenum chamber between the top, bottom and first and second surfaces; afirst rail extending from the first side surface and a second railextending from the second surface such that when the first and secondrails are slidably engaged with a third surface that is in paralleldisposition to the bottom surface, the first and second rails, thebottom surface and the third surface define a second plenum chamber;wherein: a first end of the housing defines a first plenum outlet forthe first plenum chamber on a first side of a blower device thatincludes a blower fan; the top surface defines a plenum inlet that isaligned with the blower fan so that the plenum inlet is over at least aportion of the blower fan; the bottom surface defines a second plenumoutlet that is positioned on a second side of the blower device that isopposite the first side of the blower device and that fluidly couplesthe first plenum chamber to the second plenum chamber formed by firstand second rails, the bottom surface and the third surface; and thesecond plenum chamber formed by the first and second rails, the bottomsurface and the third surface has a third plenum outlet.
 2. Theapparatus of claim 1, wherein: the first plenum outlet at the first endof the first housing defines an outlet plane substantially parallel to aradial axis of the blower device; and the third plenum outlet defines anoutlet plane substantially parallel to the radial axis of the blowerdevice on the first side of the blower device.
 3. The apparatus of claim1, further comprising an electrical connector positioned on the bottomsurface such that the electrical connector is within the second plenumchamber formed by the first and second rails, the bottom surface and thethird surface.
 4. The apparatus of claim 3, wherein the electricalconnector has a height that is less than a height of the first andsecond rails.
 5. The apparatus of claim 4, wherein the electricalconnector is positioned on a side of the second plenum outlet that isopposite a side at which the blower device is positioned longitudinallyrelative to the second plenum outlet.
 6. The apparatus of claim 1,wherein first plenum inlet includes a peripheral gasket surrounding thefirst plenum inlet.
 7. The apparatus of claim 1, wherein the firstplenum chamber is further defined by a second end that extends at leastto and connected to edges of the top surface, the bottom surface, andthe first and the second side surfaces, the second end being positionedlongitudinally on the second side of the blower device.
 8. The apparatusof claim 1, further comprising: a chassis defined by front, back, top,bottom and side surfaces; a first interior surface that partiallydefines a first slot between the first interior surface and the topsurface, wherein the first slot includes first and second rail slots toslidably receive the first housing by the first and second rails of thefirst housing; a second interior surface connected to the first interiorsurface and defining a chassis chamber between the second interiorsurface and the back side surface of the chassis and a chassis chamberbetween the second interior surface and the front surface; wherein: thefront surface of the chassis includes intake ports for air intake andthe second interior surface includes exhaust ports that allow air toflow from the intake ports to the exhaust ports and into the chassischamber; the first interior surface includes a chassis chamber exhaustport that aligns with the plenum inlet of the top surface of the firsthousing; and the top surface of the chassis forms the third surface thatis in parallel disposition to the bottom surface of the first housing todefine the second plenum chamber.
 9. The apparatus of claim 8, furthercomprising: an electrical connector positioned on the bottom surfacesuch that the electrical connector is within the second plenum chamberformed by the first and second rails, the bottom surface and the thirdsurface; and a mating component positioned within the first interiorsurface such that the mating component is configured to connect with theelectrical connector upon the first and second rails being at leastpartially slidably engaged with the first and second rail slots.
 10. Theapparatus of claim 8, wherein the back surface of the chassis includesone or more exhaust ports positioned in air communication with at leasta portion of at least one of the first plenum outlet and the thirdplenum outlet, and wherein the one or more exhaust ports are configuredto pass air out of the chassis.